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| United States Patent | 5469259 |
| Link to this page | http://www.wikipatents.com/5469259.html |
| Inventor(s) | Golby; John A. (Aschaffenburg, DE);
Padgett; Miles J. (Impington, GB2);
Woodall; Stephen P. (Histon, GB2) |
| Abstract | An inteferometer is provided with a light source forming a first collimated
beam shaped to illuminate an area and a second collimated beam shaped to
illuminate a narrow line. Both of these beams are split into
orthogonally-polarized sub-beams, which are diverted outward and inward
within a compound Wollastom prism. The images of these beams are focussed
on a test surface through an objective lens, with a real splitting point
being projected to the rear focal plane of the objective lens. With light
reflected off the test surface and projected back through the compound
Wollastom prism, interference patterns are generated on the surface of a
line sensor, which is typically used with illuminated narrow lines split
by the compound prism and projected onto a moving test surface, and on the
surface of an area sensor, which is typically used with area illumination
projected onto a stationary test surface. Autofocus and automatic phase
angle correction servomechanisms are also provided within the
interferometer. |
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Title Information  |
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Drawing from US Patent 5469259 |
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Inspection interferometer with scanning autofocus, and phase angle
control features |
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| Publication Date |
November 21, 1995 |
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| Filing Date |
January 3, 1994 |
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Title Information  |
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References  |
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Public's "Guesstimation" of Royalty Value
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Market Review  |
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Technical Review  |
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Claims  |
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What is claimed is:
1. Interferometer apparatus comprising:
illumination means for generating a coherent beam, wherein said coherent
beam forms a collimated narrow line of illumination;
beam splitting means for splitting said coherent beam directed to said beam
splitting means along an optical axis, into two orthogonally polarized
sub-beams, having the same frequency, wherein said sub-beams are directed
to travel from said beam splitting means at a divergent angle from one
another, wherein each said sub-beam forms a polarized line of
illumination, beam redirecting means for directing said sub-beams
traveling at a divergent angle to travel in a convergent angle to
intersect in a plane of intersection, wherein said beam splitting means
and said beam redirecting means are configured so that motion of said beam
splitting means and said beam redirecting means, being moved together in a
lateral direction perpendicular to said optical axis, elongates an optical
path traveled by one of said sub-beams while shortening an optical path
traveled by another of said sub-beams;
beam projection means for projecting said sub-beams from said beam
redirecting means to a test surface of a test sample, wherein said each
said sub-beam projects a line on said test surface, said lines extending
in a first direction parallel to one another;
first sensing means for sensing interference patterns produced as said
sub-beams are reflected off said test surface;
scanning means for driving said test sample past said projection means in a
direction perpendicular to said first direction, with said test surface
exposed to said projection means;
phase angle sensing means for sensing a phase angle relationship between
reflections of said sub-beams from said test sample; and
phase angle controlling means for varying said phase angle relationship in
response to said phase angle sensing means, wherein said phase angle
controlling means includes lateral drive means for moving said beam
splitting means and said beam redirecting means together in said lateral
direction.
2. The interferometer apparatus of claim 1, wherein said lateral drive
means includes a piezoelectric actuator.
3. Interferometer apparatus comprising:
illumination means for generating a coherent beam, wherein said coherent
beam forms a collimated narrow line of illumination, wherein said coherent
beam additionally forms a collimated area of illumination, wherein said
illumination means includes a laser producing a collimated laser output
beam, first beam expanding means for expanding said laser output beam in a
direction of expansion to form said collimated narrow line of
illumination, second beam expanding means for expanding said laser output
beam to form said collimated area of illumination, means for directing
said collimated laser output to said first beam expanding means, and means
for combining light from said first beam expanding means and from said
second beam expanding means;
beam splitting means for splitting said coherent beam into two orthogonally
polarized sub-beams, having the same frequency, wherein said sub beams are
directed to travel from said beam splitting means at a divergent angle
from one another, wherein each of said sub-beams forms a polarized line of
illumination;
beam redirecting means for directing said sub-beams traveling at a
divergent angle to travel in a convergent angle to intersect in a plane of
intersection;
beam projection means for projecting said sub-beams from said beam
redirecting means to a test surface of a test sample, wherein said each of
said sub-beams projects a line on said test surface, said lines extending
in a first direction parallel to one another;
first sensing means for sensing interference patterns produced as said
sub-beams are reflected off said test surface, wherein, after reflection
from said test surface, said sub-beams travel through said beam projection
means, said beam redirecting means, and said beam splitting means, being
recombined and focussed on said first sensing means at a first optical
path length from said beam splitting means, and wherein said first sensing
means is configured to sense interference patterns produced by reflections
of said lines on said test surface;
second sensing means for sensing interference patterns produced by
reflections of said area of illumination on said test surface; and
scanning means for driving said test sample past said projection means in a
direction perpendicular to said first direction, with said test surface
exposed to aid projection means.
4. The interferometer apparatus of claim 3:
wherein said first beam expanding means includes a first cylindrical lens
having a surface forming part of a first cylinder with an axis extending
perpendicularly to said direction of expansion, through which said
collimated laser beam is directed to be condensed to extend along an
intermediate line extending perpendicularly to said direction of
expansion, and a second cylindrical lens having a surface forming pad of a
second cylinder with an axis extending perpendicularly to said direction
of expansion, through which light from said intermediate line is directed
to be refracted into a collimated beam extending as a line in said
direction of expansion;
wherein said second beam expanding means includes a first lens, directing
light from said collimated laser beam through a focal point, and a second
lens directing light from said focal point to form said collimated area of
illumination; and
wherein said means for directing includes a beam splitting mirror
reflecting and transmitting portions of light from said laser beam; and
wherein said means for combining .light includes a beam splitting mirror,
reflecting and transmitting light to said coherent beam.
5. The interferometer apparatus of claim 4, wherein said illumination means
additionally includes a shutter for blocking the transmission of light
from said laser through said first beam expanding means to said coherent
beam when measurements are taken with said collimated area of
illumination.
6. Interferometer apparatus comprising:
means for projecting a light beam along an optical axis, wherein said light
beam includes a first sub-beam polarized in a first direction and a second
sub-beam polarized in a second direction, said first and second directions
being perpendicular to each other and to said optical axis, wherein said
means for projecting a light beam includes, a second half-wave plate with
a crystal axis at 22.5 degrees from said first direction, and a laser
projecting a laser beam polarized in said first direction through said
second half-wave plate;
first and second Wollaston prisms aligned in a series arrangement along
said optical axis, wherein said first and second Wollaston prisms are
composed of birefringent materials having crystal axes parallel to said
first and second directions, wherein said laser beam polarized in said
first direction is projected through said second half-wave plate to said
first Wollaston prism, wherein said sub-beams are split apart within said
first Wollaston prism and directed together by said second Wollaston
prism, to intersect at a crossover point outside said second Wollaston
prism wherein said first and second Wollaston prisms are fixtured together
in a compound prism assembly, said compound prism assembly being fixtured
for movement in a direction perpendicular to said optical axis, wherein
said first and second Wollaston prisms are configured so that motion of
said compound prism assembly in said direction perpendicular to said
optical axis introduces a phase difference between said sub-beams;
an objective lens with a focal plane at said crossover point;
means for supporting a test specimen with a test surface at a front focal
plane of said objective lens;
first beam splitting means between an illumination path along which said
laser beam is directed toward said second half-wave plate, and a sensing
path; and
first sensing means for sensing interference patterns produced by the
reflection of said sub-beams from said test surface, located along said
sensing path at a first optical path length from said first Wollaston
prism;
polarization sensitive means for directing first and second portions of
light reflected from said test surface, through said objective lens and
said first and second Wollaston prisms, wherein said first portion of
light, being polarized in said first direction, is directed to a first
photodetector, and wherein said second portion of light, being polarized
in said second direction, is directed to a second photodetector; and
means for moving said compound prism assembly in response to an output
signal from said first and second photodetectors.
7. The interferometer apparatus of claim 6, wherein said means for moving
said compound prism assembly includes:
a piezoelectric actuator moving said compound prism assembly; and
a control circuit supplying an electrical signal to said piezoelectric
actuator, said control signal being generated in response to an output of
said first and second photodetectors.
8. Interferometer apparatus comprising:
means for projecting a light beam along an optical axis, wherein said light
beam includes a first sub-beam polarized in a first direction and a second
sub-beam polarized in a second direction, said first and second directions
being perpendicular to each other and to said optical axis, wherein said
means for projecting a light beam includes, a second half-wave plate with
a crystal axis at 22.5 degrees from said first direction, and a laser
projecting a laser beam polarized in said first direction through said
second half-wave plate to said first Wollaston prism;
first and second Wollaston prisms aligned in a series arrangement along
said optical axis, wherein said first and second Wollaston prisms are
composed of birefringent materials having crystal axes parallel to said
first and second directions, wherein said sub-beams are split apart within
said first Wollaston prism and directed together by said second Wollaston
prism, to intersect at a crossover point outside said second Wollaston
prism;
an objective lens with a focal plane at said crossover point;
means for supporting a test specimen with a test surface at a front focal
plane of said objective lens;
first beam splitting means between an illumination path along which said
laser beam is directed toward said second half-wave plate, and a sensing
path;
first sensing means for sensing interference patterns produced by the
reflection of said sub-beams from said test surface, located along said
sensing path at a first optical path length from said first Wollaston
prism;
focus detection beam splitting means directing third and fourth central
portions of light reflected from said test surface, through said objective
lens and said first and second Wollaston prisms, to a first slit aperture
at a second optical path length from said first Wollaston prism, and to a
second slit aperture at a third optical path length from said first
Wollaston prism, said second optical path length being less than said
first optical path length, said third optical path length being greater
than said first optical path length;
a third photodetector viewing said third central portion of light through
said first slit aperture;
a fourth photodetector viewing said fourth central portion of light through
said second slit aperture;
means for generating an error signal in response to a difference in outputs
between said third and fourth photodetectors; and
means for moving said objective lens along said optical axis in response to
said error signal.
9. Interferometer apparatus comprising:
illumination means for generating a coherent beam directed along an optical
axis;
beam splitting means disposed along said optical axis, splitting said
coherent beam into two diverging, orthogonally polarized sub-beams;
beam redirecting means directing said sub-beams to travel in a convergent
angle to intersect at a plane of intersection;
an objective lens with a first focal plane at said plane of intersection;
a test sample with a test surface exposed to said objective lens;
sensing means for sensing interference patterns produced by the combination
of said sub-beams reflected from said test sample to be returned through
said objective lens, said beam redirecting means and said beam splitting
means, said sensing beams being held at a first optical path distance from
said beam splitting means;
scanning means for moving said test sample in a direction perpendicular to
said optical axis, wherein said scanning means includes a table for
holding said test samples, means for rotating said table about an axis of
rotation, and means for moving said axis of rotation relative to said
objective lens;
autofocus means for maintaining a focussed relationship between said
objective lens and said test surface as said test surface is moved past
said objective lens by said scanning means; and
phase control means for maintaining a phase relationship between
reflections of said sub-beams off said test surface as said test surface
is moved past said objective lens, wherein said phase control means
includes polarization sensitive means for directing light from each of
said sub-beams, having been reflected off said test sample, to separate
photodetectors, and lateral means for moving said beam splitting means and
said beam redirecting means in a lateral direction, perpendicular to said
optical axis, in response to outputs of said separate photodetectors.
10. Interferometer apparatus comprising:
illumination means for generating a coherent beam directed along an optical
axis;
beam splitting means disposed along said optical axis, splitting said
coherent beam into two diverging, orthogonally polarized sub-beams;
beam redirecting means directing said sub-beams to travel in a convergent
angle to intersect at a plane of intersection;
an objective lens with a first focal plane at said plane of intersection;
a test sample with a test surface exposed to said objective lens;
sensing means for sensing interference patterns produced by the combination
of said sub-beams reflected from said test sample to be returned through
said objective lens, said beam redirecting means and said beam splitting
means, said sensing means being held at a first optical path distance from
said beam splitting means;
scanning means for moving said test sample in a direction perpendicular to
said optical axis, wherein said scanning means includes a table for
holding said test sample, means for rotating said table about an axis of
rotation, and means for moving said axis of rotation relative to said
objective lens;
autofocus means for maintaining a focussed relationship between said
objective lens and said test surface as said test surface is moved past
said objective lens by said scanning means; and
phase control means for maintaining a phase relationship between
reflections of said sub-beams off said test surface as said test surface
is moved past said objective lens, wherein said phase control means
includes polarization sensitive means for directing light from each of
said sub-beams, having been reflected off said test sample, to separate
photodetectors, and lateral means for moving said beam splitting means and
said beam redirecting means in a lateral direction, perpendicular to said
optical axis, in response to outputs of said separate photodetectors,
wherein said lateral means for moving includes a circuit providing a
signal to move said beam splitting means and said beam redirecting means
to minimize an output signal of either of said separate photodetectors.
11. Interferometer apparatus comprising:
illumination means for generating a coherent beam directed along an optical
axis;
beam splitting means disposed along said optical axis, splitting said
coherent beam into two diverging, orthogonally polarized sub-beams;
beam redirecting means directing said sub-beams to travel in a convergent
angle to intersect at a plane of intersection;
an objective lens with a first focal plane at said plane of intersection;
a test sample with a test surface exposed to said objective lens;
sensing means for sensing interference patterns produced by the combination
of said sub-beams reflected from said test sample to be returned through
said objective lens, said beam redirecting means and said beam splitting
means, said sensing beams being held at a first optical path distance from
said beam splitting means;
scanning means for moving said test sample in a direction perpendicular to
said optical axis;
autofocus means for maintaining a focussed relationship between said
objective lens and said test surface as said test surface is moved past
said objective lens by said scanning means, wherein said autofocus means
includes a first slit aperture placed at a second optical path distance
from said beam splitting means, said second optical path distance being
lees than said first optical path distance, a second slit aperture placed
at a third optical path distance from said beam splitting means, said
third optical path distance being greater than said first optical path
distance, a first focus photodetector directed at said first slit
aperture, a second focus photodetector directed at said second slit
aperture, a focus control circuit comparing outputs of said first and
second focus photodetectors, and a focus actuator moving said objective
lens along said optical axis In response to said focus control circuit;
and
phase control means for maintaining a phase relationship between
reflections of said sub-beams off said test surface as said test surface
is moved past said objective lens. |
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Claims  |
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Description  |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an interferometer, and more particularly, to an
interferometer having features suited for the inspection of moving
surfaces.
2. Background Information
A surface profile interferometer is a device for determining the roughness
of a surface or the height of a step change in the thickness of a part
being measured. Such a step change may be caused, for example, by the
application of a metal film to a substrate in the manufacture of a printed
circuit board or an integrated microcircuit. In general terms, an
interferometer is an optical instrument in which two beams of light
derived from the same monochromatic source are directed along optical
paths of different length, in which the difference in length determines
the nature of an interference pattern produced when the light beams are
allowed to interfere. Since the beams of light are derived from the same
monochromatic source, they are identical in wavelength. At equal path
distances from the source, they are also in phase with one another. Phase
differences between the beams therefore result only from differences in
path length.
The phenomenon of light wave interference results from the mutual effect of
two or more waves passing through the same region at the same time,
producing reinforcement at some points and neutralization at other points,
according to the principle of superposition.
With a photoelectric shearing interferometer, the height of a step change
in a test surface may be measured using polarized light passed through a
slit, through a Wolloston prism, and through a microscope objective lens,
to form two images of the slit, with one image on each side of the step
change. The beams reflected by the test surface pass through the lens and
the prism, with an image being formed by two orthoganally polarized beams.
The phase difference between these beams, which is determined by the
height of the step, may be measured by the linear movement of a weak lens
in a lateral direction (transverse to the beam) until the phase difference
is exactly cancelled, as determined by the use of an electro-optic
modulator, an analyzer, a photomultiplier, and a phase-sensitive detector,
which are used together to detect the phase equality of the two
interfering beams. The accuracy of the system depends on the precision to
which the linear movement of the weak lens can be measured. Thus, a
difference in phase between two orthogonal polarizations is measured, with
the beams laterally displaced by the Wollaston prism, so that the system
is not a common-path interferometer.
The Wollaston prism makes use of the phenomenon of double refraction or
birefringence, through which a crystal of a transparent anisotropic
material refracts orthogonally polarized light beams at different angles.
Crystals such as calcite, quartz, and mica exhibit this property. A
Wollaston prism includes two wedge-shaped segments held together with
adjacent polished surfaces extending along a plane at an oblique angle to
the optical axis of the device. The outer surfaces of the Wollaston prism
lie along planes perpendicular to the optical axis of the device. The two
segments of the Wollaston prism are composed of a birefringent material,
with the crystal axes of the material lying perpendicular to each other
and to the optical axis of the device.
For example, if a beam of light consisting of two sub-beams polarized
orthogonally to each other is directed along the optical axis of the
device to a Wollaston prism, the two beams will not be refracted at the
initial surface of the prism, since it lies perpendicular to the direction
of both beams. However, when the two beams reach the oblique surfaces
inner surfaces of the two segments of the prism, refraction will occur,
with the two beams being refracted at different angles because of the
birefringence of the material of which the prism segments are composed.
When the two beams reach the opposite external side of the prism, they are
again refracted.
While the above discussion describes a Wolloston prism comprising two
wedges of birefringent material, it is possible and often advantageous to
form a prism of this kind using three or more such wedges, joined at two
or more oblique planes. When this is done, the outer surfaces of the prism
remain perpendicular to the optical center of the device.
Thus, a number of methods have been developed for using interferometers to
provide accurate measurements of very small surface features. However,
since these methods are based on rather elaborate and painstaking
processes in which a very small surface area is held in place to be viewed
through an interferometer, they are difficult to apply to the materials of
a mass production process making, in large volumes, pads which would
benefit from inspection by means of interferometry. What is needed, for
example, is a way to apply a scanning process allowing a relatively large
test surface to be checked without stopping for the measurement of
individual areas. Such a process could then be applied, for example, to
disks used for data storage.
DESCRIPTION OF THE PRIOR ART
U.S. Pat. No. 3,849,003 to Velzel describes an interferometer for measuring
the roughness of a surface, including an optical system by means of which
two images of the surface, having a mutual phase difference and
displacement, are superimposed on one another. The phase difference is
provided between two beam components polarized orthogonally by means of an
electro-optical modulator. Reasonably monochromatic radiation is converted
by a collimator lens into a parallel beam of radiation applied to the
electro-optical modulator. From the modulator, there emerge sub-beams,
which are polarized at right angles to one another, and which differ in
phase from one another. This effect is achieved by applying a suitable
electrical potential in the direction of propagation of the radiation
beam. The displacement of the components is effected in an interferometer
which discriminates with respect to the direction of polarization. Using
this method, a stable interferometer having no moving parts can be built.
Velzel describes a series arrangement of two Wollaston prisms, which
produce opposite angle splittings between two orthogonally polarized
sub-beams of light entering the series arrangement. The angular splitting
occurring in the first Wollaston prism is compensated in the second such
prism. However, since the compensation is not effected in the same plane
as the splitting, the two beams are displaced from one another by a
distance which may be continuously varied by varying the distance between
the prisms.
The two Wollaston prisms shown by Velzel are similar in geometry, except
that the crystal axes of the segments in the second prism of the series
are rotated 90 degrees from the crystal axes of the corresponding segments
in the first prism. This means that a beam consisting of orthogonally
polarized sub-beams, entering the first prism parallel to the optical axis
of the device is split to leave the second prism as two transversely
displaced beams also parallel to the optical axis. Changing the lateral
position of the Wollaston prism cannot be used to effect a change in the
phase shift occurring between two beams reflected from the test specimen,
since the symmetry of the compound prism prevents such a change from
effecting the optical path lengths through the interferometer.
U.S. Pat. No. 4,320,973 to Fortunato et al shows the use of two Wollaston
prisms of different sizes in series to receive a beam along the optical
axis of the device, which is split into two diverging sub-beams in the
first such prism to be brought back together at some distance past the
second such prism. The intermediate plane of the second prism is inclined
at an twice the angle and in the opposite direction when compared to the
intermediate plane of the first prism.
In the IBM Technical Disclosure Bulletin, (Vol. 30, No. 11, p.p. 249-250),
Makosch describes a method through which the diameter and spacing of the
two laser light points produced by a device and reflected from a test
surface are chosen independently of one another. A first lens focusses a
collimated laser beam at the splitting plane of a first Wollaston prism,
which splits the beam into two perpendicularly polarized partial beams
diverging from one another at an angle. The two partial beams are
redirected by means of a second lens in directions which would result in
the beams being recombined in the intermediate image path of a microscope.
However, before the two partial beams are recombined, they are deflected
by a second Wollaston prism parallel to the optical axis of the device. In
this manner, the laser light point is split in the intermediate image
plane into two separate points. The spacing of these points changes
linearly as a function of the spacing between the second Wollaston prism
and the intermediate image plane at which recombination occurs. Thus, by
moving the second prism along the optical axis, the spacing between the
two points can be varied in a continuous (stepless) manner in this system
from a value of zero to a finite value, without impairing the focussing of
the points.
While a number of ways of building and using interferometers are described
in these examples from the prior ad, a method to use an interferometer in
a way allowing the continuous scanning of a surface being examined is not
found. Such a method is needed to match the capabilities of interferometry
with the capabilities of processes for producing parts and devices which
would benefit from examination by interferometry. In particular, a method
for scanning the relatively large surfaces of silicon wafers used in the
production of integrated circuits is needed. Also, a method is needed to
provide for the automatic focussing of an interferometer to compensate for
changes in the thickness of test samples. Furthermore, a method is needed
to provide for the automatic control of the phase shift between reflected
sub-beams, as required to maintain darkfield interferometry despite
gradual variations in the angular orientation of a test surface.
SUMMARY OF THE INVENTION
In accordance with one aspect of the invention, there is provided
interferometer apparatus including an illumination mechanism, a beam
splitting mechanism, a beam redirecting mechanism, a beam projection
mechanism, a sensing mechanism, and a scanning mechanism. The illumination
mechanism generates a coherent beam forming a collimated narrow line of
illumination. The beam splitting mechanism splits the coherent beam into
two orthogonally polarized sub-beams, having the same frequency, directed
to travel from the beam splitting mechanism at a divergent angle from one
another, with each sub-beam forming a collimated line of illumination. The
beam projection mechanism projects the sub-beams from the beam redirecting
mechanism to a test surface, with each sub-beam projecting a line on the
test surface, with the lines extending parallel to one another. The
sensing mechanism senses interference patterns produced when the sub-beams
are reflected off the test surface. The scanning mechanism drives the test
sample past the projection mechanism with the test surface exposed to the
projection mechanism.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred embodiment of the subject invention is hereafter described with
specific reference being made to the following Figures, in which:
FIG. 1 is a schematic elevational view of an interferometer built in
accordance with the present invention;
FIG. 2 is a schematic cross-sectional plan view of a portion of an
illumination arm of the interferometer of FIG. 1, taken as indicated by
section lines II--II in FIG. 1;
FIG. 3 is a schematic cross-sectional elevation showing a light pattern
projected from the illumination arm of the interferometer of FIG. 1, taken
as indicated by section lines III--III in FIG. 1;
FIG. 4 is schematic cross-sectional plan view showing light patterns
projected through a first half-wave plate of the interferometer of FIG. 1,
taken as indicated by section lines IV--IV in FIG. 1;
FIG. 5 is a schematic elevational view of a compound Wollaston prism built
in accordance with an embodiment of the present invention;
FIG. 6 is a schematic cross-sectional plan view showing light patterns
projected through a half-wave plate within the compound Wollaston prism of
FIG. 5, taken as indicated by section lines VI--VI in FIG. 5;
FIG. 7 is a schematic plan view of a light pattern produced by the
interferometer of FIG. 1 on a surface being tested, taken as indicated by
section lines VII--VII in FIG. 1; and
FIG. 8 is a schematic elevational view of an alternative beam splitting
portion of a phase angle control servomechanism built in accordance with
the present invention.
DETAILED DESCRIPTION
As shown in FIG. 1, an interferometer 10 is a common mode shearing type,
producing a pair of sheared optical beams 12 and 14 both incident on a
surface 16 being inspected. The sheared beams 12 and 14 are produced by a
compound Wollaston prism 18, which projects a real splitting point in the
rear focal plane of a microscope objective 20. The objective lens 20 forms
interferograms of portions of surface 16 on both an area array CCD sensor
22, used for static surface acquisition, and a line scan CCD sensor 24,
used for moving surface acquisition as the test surface 16 is moved past
objective 20 in the direction of arrow 25. A dual-purpose illumination arm
26 provides both area and line illumination.
In the case of the acquisition of static surface information with area
illumination, the interferogram at area array CCD sensor 22 is a dual
image of the surface 16, with features laterally displaced by the amount
of shear between beams 12 and 14 at test surface 16. These two images,
formed using light beams of orthogonal polarities, are brought together at
area array sensor 24. Since, when the two images are compared, the
interference pattern resulting from an individual defect on test surface
16 is displaced, from one image to another, through the distance in which
beams 12 and 14 are sheared, two interference patterns of such a defect
appear, providing a form in which either interference pattern can be
analyzed if the beams 12 and 14 are sheared sufficiently to avoid
overlapping these patterns.
In the case of the acquisition of moving surface information, images of the
two bright lines produced at the ends of sheared beams 12 and 14 along
test surface 16, moving in the direction of arrow 25, are reflected upward
through the interferometer 10, to be combined in an overlapping fashion at
line scan CCD sensor 24. The illuminated lines formed on test surface 16
are sufficiently separated that a typical defect in test surface 16
appears in only one line at a time; therefore, only a single image of such
a defect occurs at a time on the line of sensor 24.
Illumination arm 26 includes a laser 28, which produces a coherent and
collimated light beam 30, having a diameter of about 0.7 mm, polarized to
vibrate into and out of the plane of the drawing of FIG. 1, in the
direction indicated by arrow 31. A beam splitting mirror 32 at the output
of laser 28 divides the light beam 30 into a first portion directed along
an upper light path 33 and a second portion directed along a lower light
path 34.
Upper light path 33 includes a first lens 36, a diffuser 38, and a second
lens 40 having a focal length substantially longer than that of first lens
36. Lenses 36 and 40 are arranged so that their focal points coincide at
diffuser 38. In this way, while the light beam 42 projected from lens 40
is collimated, as is the light beam 30 from laser 28, light beam 42 has a
substantially larger diameter than light beam 30. Diffuser 38 is included
to improve the uniformity of light levels within light beam 42.
FIG. 2 is a schematic cross-sectional plan view of lower light path 34,
taken as indicated by section lines II--II in FIG. 1. Various elements of
this path are best understood by referring to both FIGS. 1 and 2. Thus,
lower light path 34 includes a first cylindrical lens 44, a second
cylindrical lens 46 and a third cylindrical lens 48, which are together
arranged to produce an elongated light pattern of particular value in the
inspection of a scanning, or moving test surface 16. Each cylindrical lens
includes, for example, a fiat surface 50 at one side and a curved surface
52, formed as a section of a cylinder, at an opposite side. First
cylindrical lens 44 and second cylindrical lens 46 are both oriented so
that the axes of their cylindrically curved surfaces 52 extend parallel to
the optical axis 54 of interferometer 10. Third cylindrical lens 48 is
oriented so that the axis of its cylindrically curved surface 52 extends
perpendicularly to optical axis 54 and parallel to the direction indicated
by arrow 31.
While the shape of the light beam 55 travelling along lower path 34, as
viewed from the side, in the plane of FIG. 1, is virtually unchanged by
first cylindrical lens 44 and second cylindrical lens 46, this beam is
driven into a gradual convergence, or narrowing in this plane by passage
through third cylindrical lens 48.
Referring to FIG. 2, first cylindrical lens 44 and second cylindrical lens
46 are arranged to have focal axes along a common line 56, extending
parallel to the interferometer optical axis 54 (shown in FIG. 1). The
radii of curvature of the curved surfaces of these lenses 44 and 46 are
also chosen so that, as viewed in FIG. 2, light beam 54a is spread to a
widened beam 55 passing through these cylindrical lenses. Because of its
orientation, third cylindrical lens 48 does not significantly change the
shape of light beam 55 as it is viewed in FIG. 2.
Referring again to FIG. 1, upper light beam 42 and lower light beam 55 are
combined at a beam splitting mirror 60, to be projected into the remaining
portion of interferometer 10 through a field lens 62.
FIG. 3 is a schematic view of the light beams projected from illumination
arm 26, being taken as a cross-sectional elevation along section lines
III--III in FIG. 1. Referring to FIG. 3, the light from upper path 33 is
projected as a round collimated light beam 64, while the light from lower
path 34 is projected as a horizontally oriented narrow beam 66. Both round
beam 64 and narrow beam 66 are polarized in the direction of arrow 31, and
both of these beams are collimated.
Referring again to FIG. 1, the light beams projected from illumination arm
26 are directed downward, along optical axis 54 by means of a polarizing
beam splitter 68. Advantage is preferably taken of the fact that both
light beams from illumination arm are polarized in the direction of arrow
31. It is possible to reflect up to 90 percent of the polarized light
downward, along axis 54, while only 10 percent of this polarized light is
transmitted through polarizing beam splitter 68. While only a relatively
narrow beam is shown travelling through interferometer 10 outside
illumination arm 26, this simplification has been provided simply to avoid
obscuring the clarity of the drawing; it is understood that the relatively
wide area beam from upper light path 33 is also present.
FIG. 4 is a schematic plan view, taken as indicated by section lines IV--IV
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